Collection and validation of data from visual displays

ABSTRACT

A mobile computing device for providing an indication of process readings of a machine includes a processor configured to receive an image of a process indicator wherein capture of the image is initiated using the mobile computing device proximate the machine. The at least one processor is also configured to determine a template including a template image of the process indicator and template components of the process indicator. The at least one processor is further configured to display the received image and the determined template image such that they overlay each other and align the received image with the determined template image. The at least one processor is also configured to determine a position of a value indicator with respect to a scale of the process indicator, transform the determined position to a process indicator value, and store the process indicator value in the one or more memory devices.

CROSS REFERENCE TO RELATED APPLICATION

This application is a continuation of and claims priority under 35U.S.C. § 120 to U.S. patent application Ser. No. 14/967,913, filed Dec.14, 2015, the entire contents of which is hereby expressly incorporatedby reference herein.

BACKGROUND

The present disclosure relates generally to inspection systems and, morespecifically, to inspection systems and methods for capturing data fromprocess indicators and validating the integrity of the collected data.

Machine monitoring and diagnostics can be seen as a decision-supporttool which is capable of identifying the cause of failure in a machinecomponent or system, such as a power generator, as well as predictingits occurrence from a symptom. Without accurate detection andidentification of the machine fault, maintenance and productionscheduling cannot be effectively planned and the necessary repair taskscannot be carried out in time. Therefore, machine monitoring anddiagnostics are essential for an effective, predictive maintenanceprogram.

At least one purpose of using machine monitoring and diagnostics is toincrease equipment availability, as well as reduce maintenance andunexpected machine breakdown costs. In order to maximize availability,system managers often work to increase reliability by maximizing themachine uptime and, at the same time, increase maintainability byminimizing the mean time to repair. As a result of monitoring anddiagnostics, the frequency of unexpected machine breakdown may besignificantly reduced, and machine problems may be pinpointed morequickly.

In some known monitoring systems, machine monitoring and diagnostics maybe done by simply listening to the sound generated during machineoperation, or by visually examining the quality of machined parts todetermine machine condition. However, many machine faults, for example,wear and cracks in bearings and gearboxes, are not accurately assessedby relying only on visual or aural observations, especially duringoperation. In some known systems, operators collect data on machineconditions through visual inspection of machine process indicators, andmay enter such data into a historical data tracking computing system.However, such systems are prone to operator error. For example, anoperator may misinterpret or misread a generator process indicator, forexample, the operator may perceive a process indicator value of 5.605from a digital process indicator that is actually showing a value of5,605, or may read the wrong generator process indicator for example,collect and input a process indicator value from the wrong generator, orfrom the wrong process indicator at the correct generator.

Therefore, more sophisticated data collection and analysis techniqueshave been developed to help the maintenance technician and engineercollect data used for detecting and diagnosing machine failures.

BRIEF DESCRIPTION

In one embodiment, a mobile computing device for providing an indicationof process readings of a machine includes a memory device, a displaydevice, a camera, and at least one processor. The at least one processoris configured to receive an image of a process indicator from thecamera, wherein capture of the image is initiated by a user of themobile computing device while the user is proximate the machine anddetermine a template associated with the process indicator, the templateincluding a template image of the process indicator and templatecomponents of the process indicator. The at least one processor isfurther configured to display the received image and the determinedtemplate image such that one of the received image and the determinedtemplate image overlay the other of the received image and thedetermined template image and align the received image with thedetermined template image. The at least one processor is also configuredto determine a position of a value indicator with respect to a scale ofthe process indicator, transform the determined position to a processindicator value, and store the process indicator value in the one ormore memory devices.

In another embodiment, a computer-based method for providing anindication of process readings of a machine using a mobile computingdevice coupled to a user interface, and camera, and a memory deviceincludes receiving an image of a process indicator from the camera,wherein capture of the image is initiated by a user of the mobilecomputing device while the user is proximate the machine. The methodalso includes determining a template associated with the processindicator, the template including a template image of the processindicator and template components of the process indicator. The methodfurther includes displaying the received image and the determinedtemplate image overlaid together. The method also includes aligning thereceived image with the determined template image, determining aposition of a value indicator with respect to a scale of the processindicator, transforming the determined position to a process indicatorvalue, and storing the process indicator value in the one or more memorydevices.

In yet another embodiment, one or more non-transitory computer-readablestorage media having computer-executable instructions embodied thereon,wherein when executed by at least one processor of a mobile computingdevice cause the processor to receive an image of a process indicatorfrom the camera, wherein capture of the image is initiated by a user ofthe mobile computing device while the user is proximate the machine. Thecomputer-executable instructions further cause the processor todetermine a template associated with the process indicator, the templateincluding a template image of the process indicator and templatecomponents of the process indicator and display the received image andthe determined template image overlaid together. The computer-executableinstructions also cause the processor to align the received image withthe determined template image, determine a position of a value indicatorwith respect to a scale of the process indicator, transform thedetermined position to a process indicator value, and store the processindicator value in the one or more memory devices.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1-7 show example embodiments of the method and system describedherein.

FIG. 1 is a diagram of an exemplary machine environment in which a fieldoperator collects process indicator values from one or more assets usingan exemplary inspection system.

FIG. 2 is a diagram of an exemplary sensor panel associated with anasset of the one or more assets shown in FIG. 1 and on which are mounteda plurality of process indicators.

FIG. 3 is an exemplary digital image of a portion of the sensor panelshown in FIG. 2.

FIG. 4 is an exemplary template frame for the process indicator shown inFIG. 3.

FIG. 5 is an illustration of the operator shown in FIG. 1 using theexemplary inspection system shown in FIG. 1, including the inspectiondevice, to capture sample data from the subject process indicator.

FIG. 6 illustrates an exemplary field-of-view display on inspectiondevice as provided by camera 132 during the exemplary sample collectiondescribed above in reference to FIG. 5.

FIG. 7 is a flow chart of an exemplary computer-based method forproviding an indication of process readings of a machine.

Although specific features of various embodiments may be shown in somedrawings and not in others, this is for convenience only. Any feature ofany drawing may be referenced and/or claimed in combination with anyfeature of any other drawing.

Unless otherwise indicated, the drawings provided herein are meant toillustrate features of embodiments of the disclosure. These features arebelieved to be applicable in a wide variety of systems comprising one ormore embodiments of the disclosure. As such, the drawings are not meantto include all conventional features known by those of ordinary skill inthe art to be required for the practice of the embodiments disclosedherein.

DETAILED DESCRIPTION

In the following specification and the claims, reference will be made toa number of terms, which shall be defined to have the followingmeanings.

The singular forms “a,” “an,” and “the” include plural references unlessthe context clearly dictates otherwise. “Optional” or “optionally” meansthat the subsequently described event or circumstance may or may notoccur, and that the description includes instances where the eventoccurs and instances where it does not.

Approximating language, as used herein throughout the specification andclaims, may be applied to modify any quantitative representation thatmay permissibly vary without resulting in a change in the basic functionto which it is related. Accordingly, a value modified by a term orterms, such as “about” and “substantially,” are not to be limited to theprecise value specified. In at least some instances, the approximatinglanguage may correspond to the precision of an instrument for measuringthe value. Here and throughout the specification and claims, rangelimitations may be combined and/or interchanged, such ranges areidentified and include all the sub-ranges contained therein unlesscontext or language indicates otherwise.

As used herein, the term “non-transitory computer-readable media” isintended to be representative of any tangible computer-based deviceimplemented in any method or technology for short-term and long-termstorage of information, such as, computer-readable instructions, datastructures, program modules and sub-modules, or other data in anydevice. Therefore, the methods described herein may be encoded asexecutable instructions embodied in a tangible, non-transitory, computerreadable medium, including, without limitation, a storage device and/ora memory device. Such instructions, when executed by a processor, causethe processor to perform at least a portion of the methods describedherein. Moreover, as used herein, the term “non-transitorycomputer-readable media” includes all tangible, computer-readable media,including, without limitation, non-transitory computer storage devices,including, without limitation, volatile and nonvolatile media, andremovable and non-removable media such as a firmware, physical andvirtual storage, CD-ROMs, DVDs, and any other digital source such as anetwork or the Internet, as well as yet to be developed digital media,with the sole exception being a transitory, propagating signal.

As used herein, the terms “software” and “firmware” are interchangeable,and include any computer program stored in a memory device for executionby devices that include, without limitation, mobile computing devices,clusters, personal computers, workstations, clients, and servers.

As used herein, a “camera” refers to an image capture device or photosensor configured to transfer a captured image of an object to acomputer readable memory device. As used herein, a camera will generallyrefer to a digital image capture device unless otherwise specified.Additionally, a camera will generally be integrated into a mobile,handheld, and wireless digital device unless otherwise specified.

Embodiments of the disclosed subject matter describe inspection systemsthat use a camera to capture images of gauges or other processindicators and convert those captured images into the process valuesrepresented on the gauge into an electronic format. Other embodimentsare within the scope of the disclosed subject matter. The inspectionsystems also validate the integrity of the collected data.

A data collection system, device, and method described herein providefor collection and validation of data from process indicators and visualdisplays. In one exemplary embodiment, a field operator collectsoperating parameters, such as, but not limited to, motor speed,temperature, flow rate, associated with an asset, for example, a powergenerator, or associated components, such as turbines, pumps,compressors, or the like, using a portable or handheld data collectiondevice, herein referred to as the “handheld device.” For example, thefield operator may walk a “route” within a power generation facilitythat includes a plurality of power generators, each generator having oneor more process indicators or gauges that provide data that may becollected and analyzed to monitor machine health. The field operatoruses the handheld device, for example, a mobile computing device, suchas a tablet or smartphone that includes a camera to capture and processimages of the process indicators. The collection system is configured todetermine the process indicator value (“sample value”) from the imageand, in some embodiments, transmit this process indicator value from thehandheld device to a monitoring server.

To facilitate proper data collection, the process indicator datacollection system is pre-configured with a “template frame” for each ofa plurality of process indicators. More specifically, a user configuresa subject process indicator for use with the process indicator datacollection system by capturing a representative image (“model image”) ofthe subject process indicator. The user then constructs a template framefor the subject process indicator using a configuration module. In oneexample embodiment, the configuration module displays the sample imageto the user and the user creates one or more framing elements aroundstructural or visually-distinguishing features on or over the modelimage, such as the outer edges of the subject process indicator, text orfeatures within or near the subject process indicator, or the outline ofother nearby process indicators or other visible features. During datacollection, the field operator approaches the subject process indicatorand orients the handheld device toward the subject process indicator. Onthe display screen, the collection device projects a real-time displayof the subject process indicator as viewed through a camera. Further,the collection device overlays the template frame for the subjectprocess indicator onto the display. On the display, the real-timedisplay from the camera may change (e.g., as the field operator movesthe device) but, in some embodiments, the template frame remainsstationary. As such, the field operator physically reorients thecollection device until the real-time display of the process indicatorapproximately matches the template frame (e.g., until the framingelements of the template frame are approximately aligned with the visualelements of the process indicator and surrounding environment). Forexample, the field operator may move the collection device slightly tothe left/right, or up/down, or farther or nearer from the subjectprocess indicator until elements of the template frame are appropriatelyaligned. In some embodiments, once the frame appears to be aligned, thefield operator collects a digital image of the process indicator(“sample image”). In other embodiments, the collection device isconfigured to determine that alignment has been achieved andautomatically collect the sample image.

Once the sample image is collected, the process indicator datacollection system identifies the process indicator value (“samplevalue”) from the sample image using, e.g., pattern recognitiontechniques. The process indicator value is then compared topre-configured data about the subject process indicator, such as anexpected (e.g., normal) operating range. The collection device thendisplays the sample value (as interpreted from the image) and warns thefield operator if the sample value is outside the expected operatingrange. The field operator may then accept the displayed value, re-takethe image, manually enter a value, or elect to cancel/skip collectionfor this process indicator. If the sample value is accepted, that samplevalue, and in some embodiments the sample image, is stored and/ortransmitted to a data collection system for use in, e.g., monitoring oranalyzing machine performance or health. As such, the process indicatordata collection system facilitates more reliable collection andvalidation of data from process indicators and other visual displays.

As used herein, the term “real-time display” is used to refer to theimages displayed on the display of a handheld device while the handhelddevice's camera is active. As is typical with many known handhelddevices having integrated or attached cameras, the handheld deviceincludes a camera, which, when active, continuously captures imagesthrough the camera and continuously displays those images on thedisplay. In other words, the user sees what looks like an ongoing,full-motion, real-time “movie” through the perspective of the camera anddisplayed on the mobile device's screen. The term “image” is used hereinto refer to a static graphic or “picture,” e.g., as captured by thecamera when a digital image is collected. As such, since static imagesand the real-time display are captured through the camera, the real-timedisplay may be used, for example, to approximate what a static image maylook like if collected at that moment.

FIG. 1 is a diagram of a machine environment 100 in which a fieldoperator (“operator”) 106 collects process indicator values from one ormore assets 120 such as, but not limited to, turbine engines using anexemplary inspection system 102 that includes an inspection device 104,including a processor 108 and a memory device 109, communicativelycoupled to a server device 110 and a database 114 through for example, awired connection, a wireless transceiver, and/or a wireless networkadapter 112. In the exemplary embodiment, machine environment 100 is apower generation environment that includes a plurality of turbines, anyof which may be regularly monitored for machine health. Operator 106walks a path or “route” 130 through environment 100 and collectsoperating parameters (“sensor data”) that may originate from respectivesensors 122. Process indicators 123 provide a visual display of a valuethat quantifies an operating parameter of asset 120 using a processindicator 123. Exemplary operating parameters include running speed of amotor of asset 120, as well as temperature, flow rate, and the like.Process indicators 123 may include any type of visual display thatenables the systems and methods described herein. For example, someprocess indicators 123 may be digital displays showing a numericreadout, other process indicators 123 may be needle displays with asweeping needle 124 and a scale 126.

In the exemplary embodiment, operator 106 carries inspection device 104while walking route 130. Inspection device 104 is embodied in a handheldmobile computing device, such as a smartphone or tablet computer, thatincludes an integrated or attached camera 132 embodied in, for example,a camera device and a display screen 134. Further, in some embodiments,inspection device 104 includes a wireless network adapter 112 embodiedin a Wi-Fi adapter or a cellular network adapter that facilitateswireless communication with, for example, server device 110 and database114. Inspection device 104 is configured to present a real-time displayto operator 106 as captured by camera 132, as well as capture images ofprocess indicators 123. In some embodiments, inspection device 104 is atablet computing device that includes a display interface that alsofunctions as an input device, and may run, for example, the Android®operating system offered by Google Inc. of Mountain View, Calif.

During operation, in the exemplary embodiment, inspection device 104presents route 130 to operator 106. For example, inspection device 104may display an ordered series of process indicator locations (e.g., asubject asset 120 a and a subject process indicator 123 a associatedwith that subject asset 120 a) such as to define route 130 for operator106. At each asset 120, for example, subject asset 120 a, operator 106stops to collect one or more “sample images” of subject processindicator 123 a. Collection and analysis of these sample images aredescribed in greater detail below.

FIG. 2 is a diagram of an exemplary sensor panel 210 associated withasset 120 a, and on which are mounted a plurality of process indicators220, also referred to as sensor displays, including subject processindicator 123 a. In the exemplary embodiment, sensor panel 210 islocated within machine environment 100 (shown in FIG. 1) near asset 120a. Process indicators 220 include a bar graph process indicator 222, adigital process indicator 224, and subject process indicator 123 a. Inthe example embodiment, subject process indicator 123 a is aneedle-style process indicator that includes scale 126 over which needle124 rotates to project the underlying value read by the sensing element.However, any style of process indicator display that enables the systemsand methods described herein may be used.

To facilitate data collection and analysis of process indicator datafrom subject process indicator 123 a, inspection system 102 (shown inFIG. 1) performs two main functions: (i) configuration of a processindicator within inspection system 102; and (ii) capture and analyze asample image.

FIG. 3 is an exemplary digital image 300 of a portion of sensor panel210 (shown in FIG. 2), including the subject process indicator 123 a andsurrounding areas. For purposes of illustration and ease of description,elements of sensor panel 210 are illustrated and referred to herein inreference to their likenesses as they appear and are shown on digitalimage 300. In the exemplary embodiment, image 300 is a digital imagetaken, collected, or otherwise captured by camera 132 integrated with orotherwise attached to a handheld device such as inspection device 104(shown in FIG. 1). Image 300 depicts portions 222 a and 224 a ofadjacent process indicators 222 and 224, but is focused primarily on thesubject process indicator 123 a, which is approximately centered withinimage 300.

Image 300, in the example embodiment, includes various structural orother visually-distinguishing features, one or more of which may be usedby inspection system 102 (shown in FIG. 1) during data collection andvalidation. For example, the subject process indicator 123 a includes aprimary display area 320 and a nearby label 340. Label 340 defines aframe boundary 342 within which characters 344 are printed (in thiscase, e.g., identifying the type of process indicator). Display area 320defines a display boundary 322 circumscribing other elements of subjectprocess indicator 123 a, such as a scale 324, fixed display labels 326and 332, and a meter needle 330 rotating about a needle center 328.Scale 324 further includes a plurality of long marks 324 a and aplurality of tic marks 324 b, each overlapping or connected to asemi-circular meter arc 324 c. Further, image 300 includesvisually-distinguishing features appearing near subject processindicator 123 a, such as a portion of a border frame 222 a, 224 a orinterior features 222 b, 224 b of nearby process indicators 222, 224.

In the example embodiment, during configuration of the subject processindicator 123 a within inspection system 102, a system user (not shown)collects a reference image or “model image” 310 of the subject processindicator 123 a. In some embodiments, a larger image 300 is cropped bythe user to generate model image 310. This model image 310 is used bythe user to construct a “template frame” associated with the subjectprocess indicator 123 a.

In the example embodiment, inspection system 102 includes aconfiguration module (not shown in FIG. 3) that enables the user todesignate image 310 as a model image for the subject process indicator123 a that is used for frame construction for subject process indicator123 a. More specifically, in one embodiment, the configuration modulepresents the model image 310 on a display device (not shown in FIG. 3),as well as provides a set of geometric tools for use in conjunction withimage 310. The geometric tools allow the user to generate one or moreframe elements or pieces of the overall template frame for subjectprocess indicator 123 a.

FIG. 4 is an exemplary template frame 400 for subject process indicator123 a (shown in FIG. 3). In FIG. 4, solid lines are used to representframe elements, or pieces of template frame 400, and dashed lines areused to represent a border 402, which is not a part of template frame400, but rather is merely for illustrative purposes to show, e.g., theapproximate size or border of model image 310. In the exemplaryembodiment, template frame 400 includes a plurality of geometric shapesor lines such as a first semi-rectangle 410, a second semi-rectangle420, a gauge circle 430, a needle center circle 440, and a plurality ofhash lines 450 a, 450 b, 450 c, and 450 d. These geometric shapes arereferred to herein as “template elements” and, collectively, make uptemplate frame 400.

In reference now to FIGS. 3 and 4, during configuration of subjectprocess indicator 123 a for use with inspection system 102 (shown inFIG. 1), the configuration component presents model image 310 on thedisplay device mentioned above. Further, the configuration moduleoverlays template frame 400 onto model image 310 such that the frameelements are aligned and displayed over model image 310 (e.g., accordingto matching border 402 with the boundaries of model image 310. Theconfiguration module also provides geometric shape-creating tools for avariety of geometric shape types such as, for example, circles,ellipses, rectangles, lines, triangles, and arcs.

The user creates one or more geometrically shaped template elements onor “over” the model image 310. More specifically, in one exemplaryembodiment, the user identifies one or more visually-distinguishingfeatures of the subject process indicator 123 a and the surrounding area(e.g., the area visible within image 300 or model image 310). The userthen creates geometric shapes to match a portion or all of thevisually-distinguishing features. For example, the user may identifydisplay boundary 322 of subject process indicator 123 a as avisually-distinguishing feature of model image 310. The user may thencreate a feature element on template frame 400 on or over the image ofdisplay boundary 322. Since the display boundary 322 is approximatelycircular in shape, the user may select a circle/ellipse geometric shapetool provided by the configuration component. With the shape tool, theuser creates gauge circle 430 (e.g., a circular-shaped feature element)onto or over model image 310 on the display. The user may resize andreposition gauge circle 430 on template frame 400 until gauge circle 430approximately aligns with display boundary 322 on model image 310. Insome embodiments, the user may use an outer edge or an inner edge ofdisplay boundary 322 with which to align gauge circle 430. In someembodiments, the user may create a template element for both the outerand inner edges of display boundary 322. In other embodiments, a widthof gauge circle 430 may be adjusted such that gauge circle 430 isapproximately the same width as a width of display boundary 322.

Similarly, the user may identify other visually-distinguishing featuresof model image 310 and create additional frame elements to reflect thosefeatures. Continuing the configuration of the exemplary template frame400, the user identifies border frames 222 a, 224 a of nearby processindicators 222, 224 as visually-distinguishing features for which theuser would like to create template elements. As such, and similarly, theuser may use a semi-rectangle shape tool (or, e.g., a plurality of linesfrom a line shape tool) to create semi-rectangles 410, 420 on templateframe 400 and align/resize those semi-rectangles 410, 420 toapproximately match border frames 222 a and 224 a, respectively.

The user may select visually-distinguishing features of model image 310to use for building template frame 400 that are not likely to changeover time, and/or be independent of current (and perhaps transient orshifting) values of the subject process indicator 123 a. Inspectionsystem 102 may provide better performance with template frame 400 ifmost or all of the template elements are “fixed,” and/or whose imageappears approximately the same regardless of the current value of thesubject process indicator. For example, needle 330 may be aless-reliable candidate for a template element because the alignment ofneedle 330 is directly tied to the current value of subject processindicator 123 a. In other words, when the underlying value of subjectprocess indicator 123 a is lower, needle 330 changes orientation (e.g.,counter-clockwise of the orientation shown in FIG. 3), and when theunderlying value of subject process indicator 123 a is higher, needle330 changes orientation (e.g., clockwise of the orientation shown inFIG. 3). As such, if a template were created with needle 330 in thealignment shown in FIG. 3 and then later used by inspection system 102to match a later-collected image of subject process indicator 123 a, thetemplate element associated with needle 330 may not match the currentimage of needle 330 if subject process indicator 123 a is not displayingthe same or approximately the same value. Similarly, anyvisually-distinguishing feature that may change or be obscured, e.g.,depending on transient or changing conditions (e.g., needle 330,interior features 224 b, 222 b, and display label 332) may be lessercandidates for template elements of template frame 400, wherevisually-distinguishing features that are not likely to change or beobscured (e.g., display label 326, display boundaries 322, 342, andborder frames 222 a, 224 a) may be more reliable or better-performingcandidates for template elements of template frame 400.

In some embodiments, the configuration component identifies one or morevisually-distinguishing features and creates one or more frame elementsof the template frame automatically. For example, the configurationcomponent may receive model image 310 and utilize optical or shaperecognition software to identify display boundary 322 of subject processindicator 123 a. The configuration component may recognize the shape ofdisplay boundary 322 as approximately circular, and may automaticallygenerate gauge circle 430 and resize and/or reposition gauge circle 430on template frame 400 to approximately overlay display boundary 322. Insome embodiments, the one or more automatically-generated frame elementsmay be presented to the user, and the user may selectively remove someor all if, for example, they are likely to change over time, or beobscured in some situations.

As such, model image 310 acts as an assisting tool or image over whichto create template frame 400, either by the user, automatically (e.g.,by the configuration tool), or some combination of both. Each templateelement overlays a particular visually-distinguishing feature of modelimage 310 such that model image 310 acts as a background onto whichtemplate frame 400 aligns. Further, the frame elements of template frame400 may be displayed in a particular color or with a particular graphiceffect such that the user can visually distinguish or pick out thetemplate elements from the background of model image 310. After the userhas completed adding one or more template elements (e.g., the elementsshown in template frame 400), the configuration component stores thetemplate frame 400 for later use (e.g., in database 114, shown in FIG.1).

It should be understood that the shape tools and geometric shapesdescribed above are exemplary. Any shape tools and/or geometric shapes,or portions thereof, which enable the systems and methods describedherein, may be provided by inspection system 102.

FIG. 5 is an illustration of operator 106 using the exemplary inspectionsystem 102 (shown in FIG. 1), including inspection device 104, tocapture sample data from the subject process indicator 123 a. Duringoperation, operator 106 is directed by inspection system 102 to collectsample data (e.g., a sample image) from subject process indicator 123 aassociated with asset 120 a. Operator 106 moves to the location of asset120 a within environment 100 (shown in FIG. 1) and approaches sensorpanel 210. In some embodiments, inspection system 102 may presentlocation information for asset 120 a, sensor panel 210, and/or subjectprocess indicator 123 a to assist in guiding operator 106 to the properlocation. Further, in some embodiments, inspection system 102 maydisplay a representative image of subject process indicator 123 a oninspection device 104 to, for example, assist operator 106 in collectingsample data from the proper process indicator 123, in this case, subjectprocess indicator 123 a. The representative image may be, for example,model image 310 (shown and described above in reference to FIG. 3), or apast sample image of subject process indicator 123 a.

In the exemplary embodiment, operator 106 activates inspection system102 (e.g., via inspection device 104) to begin the sample collectionprocess for subject process indicator 123 a. Inspection device 104activates camera 132 (not separately shown in FIG. 5) and operator 106orients inspection device 104 toward subject process indicator 123 a.Inspection device 104 displays a real-time image, as provided by camera132, in a display area 510 of inspection device 104. More specifically,because of the particular orientation of camera 132, inspection device104 displays a real-time image of field-of-view 520 of a portion ofsensor panel 210 including subject process indicator 123 a.

FIG. 6 illustrates an exemplary field-of-view 520 display on inspectiondevice 104 as provided by camera 132 during the exemplary samplecollection described above in reference to FIG. 5. Elements in FIG. 6may be similar to elements as shown and described in relation to FIG. 3.In the exemplary embodiment, inspection device 104 includes a displaydevice 604 on which real-time and static images from camera 132 arepresented. In the exemplary embodiment, display device 604 illustratesonly a single, complete display area 510 for presenting such images to auser, such as operator 106. In other embodiments, portions of displayarea 510 may be used for buttons or other functionality, and the imagesmay be displayed in a display area less than the entire display area.

Referring now to FIGS. 5 and 6, inspection system 102 presents both areal-time field-of-view 520 display on inspection device 104 (e.g., ondisplay area 510) as well as an overlay of template frame 400 on displaydevice 604. In FIG. 6, real-time field-of-view 520 elements such assample gauge edges 610 and 620, sample gauge edge 630, and sample needlecenter 640 (collectively referred to herein as the sample elements,which may also include other elements not separately identified in FIG.6) are illustrated in solid lines and template frame 400 elements suchas template semi-rectangles 410 and 420, template gauge circle 430, andtemplate needle center circle 440 (collectively referred to herein astemplate elements) are illustrated in broken lines.

In the exemplary embodiment, the template elements are overlaid onto(e.g., displayed over, and simultaneously with) the real-time imagedisplay of field-of-view 520. In other words, operator 106 sees both thereal-time image from camera 132 as well as the template elements. Insome embodiments, the template elements may be displayed in a particularcolor, such as white or yellow, such as to be distinguishable on the“background” of the real-time image (e.g., from the sample elements). Insome embodiments, the template elements may be displayed as broken-linedelements, such as shown in FIG. 6.

During operation, and as illustrated in FIG. 6, operator 106 hasinspection device 104 and camera 132 oriented such that the real-timeimage (e.g., the sample elements 610, 620, 630, 640) are not alignedwith the template elements (e.g., template elements 410, 420, 430, 440).More specifically, inspection device 104 is oriented high and to theright in relation to the template elements such that the sample elementsappear low and to the left of the template elements. With the templateelements as an indicator of proper positioning, operator 106 thenreorients inspection device 104, changing field-of-view 520, until thetemplate elements approximately match up with (e.g., are displayed over)their counterpart sample elements. In other words, to correct thealignment deficiency as shown in FIG. 6, operator 106 would reorientcamera 132 lower and to the left until the template elements alignedwith the sample elements.

In the example embodiment, misalignment is only illustrated in twodirections (e.g., high/low and left/right) for ease of illustration. Itshould be understood that other misalignments are possible. For example,operator 106 may position inspection device 104 too far or too near tosubject process indicator 123 a relative to template frame 400. In sucha misalignment, the sample elements may appear larger or smallerrelative to the template elements. For example, if operator 106 holdsinspection device 104 too close to subject process indicator 123 a,sample gauge edge 630 may appear larger than (e.g., of greater diameterthan) the associated template gauge circle 430. As such, to correctthese types of misalignments, operator 106 may need to move inspectiondevice 104 closer to or farther away from subject process indicator 123a, thereby changing field-of-view 520, and thereby altering the shapesof the sample elements in the real-time view as compared to the templateelements. Similarly, operator 106 may position inspection device 104 toohigh and looking down toward, or too low and looking up toward subjectprocess indicator 123 a. As such, the sample elements may appearaccordingly contorted. For example, sample gauge edge 630 may appear asan oval shape rather than circular, like the associated template gaugecircle 430. To correct these types of misalignments, operator 106 mayneed to hold inspection device 104 higher or lower. It should also beunderstood that various combinations of the above-described types ofmisalignments are possible.

Once aligned, operator 106 initiates collection of a sample image (notseparately shown in FIG. 6) of subject process indicator 123 a, shown infield-of-view 520 that includes subject process indicator 123 a). In oneembodiment, display area 510 includes a pressable virtual buttonconfigured to allow operator 106 activate camera 132 to capture thesample image.

In the exemplary embodiment, upon capture of the sample image,inspection system 102 processes the sample image and extracts a sampleprocess indicator value from the sample image. In some embodiments,inspection device 104 may process the sample image. In otherembodiments, inspection device 104 may transmit the sample image toinspection server device 110 (shown in FIG. 1) for processing, andinspection server device 110 may transmit the sample process indicatorvalue back to inspection device 104.

In some embodiments, inspection device 104 may display the sampleprocess indicator value to operator 106. In some embodiments, inspectionsystem 102 may compare the sample process indicator value to apre-defined target process indicator value and/or a target processindicator range. If the sample process indicator value deviates from thetarget process indicator value by a pre-determined threshold amount,inspection system 102 may display an alert (e.g., via inspection device104) to operator 106 indicating, for example, an error in the sampleimage (e.g., perhaps operator 106 captured the sample image from asimilar but incorrect process indicator), or an asset operating outsideof norms for that asset.

FIG. 7 is a flow chart of an exemplary computer-based method 700 forproviding an indication of process readings of a machine. In the exampleembodiment, method 700 is implemented using a handheld device coupled toa user interface, a camera, and a memory device. Method 700 includesreceiving 702 an image of a process indicator from the camera, whereincapture of the image is initiated by a user of the handheld device whilethe user is proximate the machine. Method 700 also includes determining704 a template associated with the process indicator, the templateincluding a template image of the process indicator and templatecomponents of the process indicator. The template image is an image thatrepresents a face of the process indicator, such as, but not limited toan actual previously captured image of that process indicator, anothersimilar process indicator, or a rendition of the process indicator thatis dimensional proportional to the actual process indicator, or otherrendition of the process indicator. The template components include, forexample, a scale range, threshold limits, and/or ranges, identifyingfeatures, input range, calibration information, and the like. Method 700further includes displaying 706 the received image and the determinedtemplate image such that one of the received image and the determinedtemplate image overlay the other of the received image and thedetermined template image.

Method 700 also includes aligning 708 the received image with thedetermined template image, determining 710 a position of a valueindicator with respect to a scale of the process indicator, transforming712 the determined position to a process indicator value, and storing714 the process indicator value in the one or more memory devices.

As will be appreciated based on the foregoing specification, theabove-discussed embodiments of the disclosure may be implemented usingcomputer programming or engineering techniques including computersoftware, firmware, hardware or any combination or subset thereof. Anysuch resulting program, having computer-readable and/orcomputer-executable instructions, may be embodied or provided within oneor more computer-readable media, thereby making a computer programproduct, i.e., an article of manufacture, according to the discussedembodiments of the disclosure. The computer readable media may be, forinstance, a fixed (hard) drive, diskette, optical disk, magnetic tape,semiconductor memory such as read-only memory (ROM) or flash memory,etc., or any transmitting/receiving medium such as the Internet or othercommunication network or link. The article of manufacture containing thecomputer code may be made and/or used by executing the instructionsdirectly from one medium, by copying the code from one medium to anothermedium, or by transmitting the code over a network. The technical effectof the methods and systems may be achieved by performing at least one ofthe following steps: (a) receiving an image of a process indicator fromthe camera, wherein the receiving of the image is initiated using themobile computing device while the mobile computing device is proximatethe machine, (b) determining a template associated with the processindicator wherein the determined template includes a template image ofthe process indicator and template components of the process indicator,(c) displaying the received image and the determined template imageoverlaid together, (d) aligning the received image with the determinedtemplate image, (e) determining a position of a value indicator withrespect to a scale of the process indicator, (f) transforming thedetermined position to a process indicator value, and (g) storing theprocess indicator value in the memory device.

The above-described embodiments of a method and system of acquiringprocess information using image data and a preconfigured template frameprovides a cost-effective and reliable means for assist the data-entryof values from industrial process indicators, both digital andanalog/dial types, by using a camera which is integral to the datacollection device. More specifically, the methods and systems describedherein facilitate image processing techniques to extract the processindicator value from the image. In addition, the above-described methodsand systems facilitate pre-configuring, for each process indicator to beread, information, such as, but not limited to minimum and maximumvalues, the units of measure, and the database location where this valueshould be stored. Furthermore a sample photo of the process indicatorpermits consistent alignment of the camera and reliable automatedreading of the correct process indicator, with accuracy. As a result,the methods and systems described herein facilitate maintenance andcondition monitoring of equipment in a cost-effective and reliablemanner.

This written description uses examples to describe the disclosure,including the best mode, and also to enable any person skilled in theart to practice the disclosure, including making and using any devicesor systems and performing any incorporated methods. The patentable scopeof the disclosure is defined by the claims, and may include otherexamples that occur to those skilled in the art. Such other examples areintended to be within the scope of the claims if they have structuralelements that do not differ from the literal language of the claims, orif they include equivalent structural elements with insubstantialdifferences from the literal language of the claims.

1-21. (canceled)
 22. An apparatus comprising: a memory; a display; acamera; and at least one processor configured to: receive an image of aprocess indicator from the camera, wherein receiving the image isinitiated using the apparatus after the apparatus is carried to alocation proximate a machine; determine a template from a plurality ofstored templates, the template associated with a process indicator of aplurality of process indicators, the template retrieved from the memory,the template including a template image of the process indicator andtemplate components of the process indicator; and display the receivedimage and the determined template image such that the received imageoverlays the determined template image or the determined template imageoverlays the received image.
 23. The apparatus of claim 22, wherein theat least one processor is further configured to characterize the processindicator using at least one of a shape of a bezel of the processindicator a shape of the scale of the process indicator, labelsproximate the process indicator, and a color scheme of the processindicator.
 24. The apparatus of claim 23, wherein the at least oneprocessor is further configured to optically recognize the labels. 25.The apparatus of claim 24, wherein the at least one processor is furtherconfigured to identify the process indicator using at least one of thecharacterization and the labels.
 26. The apparatus of claim 22, whereinthe at least one processor is further configured to: transform the atleast one of the determined position and the determined characters to aprocess value; and store the process value in the memory device.
 27. Theapparatus of claim 22, wherein the at least one processor is furtherconfigured to: extract one or more features of (he process indicator inthe received image; and retrieve a template image from a plurality ofpredetermined template images stored in the memory, the retrievedtemplate image including predetermined features that match the extractedone or more features of the process indicator in the received image. 28.The apparatus of claim 22, wherein the at least one processor is furtherconfigured to: correlate a position of the value indicator to a templateposition on the determined template image, the position of the valueindicator in the received image determined with respect to a scale ofthe process indicator shown in the received image and characters of adigital process indicator; and determine a process indicator displayedvalue based on the correlated position.
 29. The apparatus of claim 22,wherein the template components of the process indicator include alleast one of a scale range, a scale minimum value, a scale maximumvalue, scale increments, and thresholds associated with the processindicator.
 30. The apparatus of claim 22, wherein the at least oneprocessor is further configured to: determine that an alignment of thereceived image with the determined template image has been achieved, thealignment including aligning visual elements in the received image andsurrounding environment with corresponding frame elements of thedetermined template image; and automatically collect the process value.31. A method comprising: receiving, by an apparatus, an image of aprocess indicator captured from a camera of the apparatus, whereinreceiving the image is initiated using the apparatus while the apparatusis proximate to a machine, the apparatus including a memory, a display,the camera, and at least one processor being integrated within theapparatus; determining, by the apparatus, a template associated with theprocess indicator from a plurality of stored templates, the determinedtemplate including a template image of the process indicator capturedfrom the camera and template components of the process indicator; anddisplaying the received image and the determined template image suchthat the received image overlays the determined template image or thedetermined template image overlays the received image. aligning visualelements in the received image and surrounding environment withcorresponding framing elements of the determined template image;determining a position of a value indicator with respect to a scale ofthe process indicator; transforming the determined position to a processindicator value; and storing the process indicator value in the memorydevice.
 32. The method of claim 31, wherein the method further comprisescharacterizing the process indicator using at least one of a shape of abezel of the process indicator, a shape of the scale of the processindicator, labels proximate the process indicator, and a color scheme ofthe process indicator.
 33. The method of claim 32, wherein the methodfurther comprises optically recognizing the labels.
 34. The method ofclaim 33, wherein the method farther comprises identifying the processindicator using at least one of the characterization and the labels. 35.The method of claim 31, wherein the method further comprises: extractingone or more features if the process indicator in the received image; andretrieving a template from a plurality of predetermined templates storedin the memory, the retrieved template including predetermined featuresthat match the extracted one or more features of the process indicatorin the received image.
 36. The method of claim 31, wherein the methodfurther comprises: correlating a determined position of the valueindicator to a template position on the determined template image, theposition of the value indicator in the received image determined withrespect to a scale of the process indicator shown in the received imageand characters of a digital process indicator; and determining a processindicator displayed value based on the correlated position.
 37. Themethod of claim 31, further comprising storing, by the apparatus,template components of the process indicator that include at least oneof a scale range, a scale minimum value, a scale maximum value, scaleincrements, and thresholds associated with the process indicator. 38.One or more non-transitory computer-readable storage media havingcomputer-executable instructions, embodied thereon, wherein whenexecuted cause the processor to: receive an image of a process indicatorfrom a camera of an apparatus, wherein receiving the image is initiatedusing the apparatus while the apparatus is proximate to a machine, theapparatus including a memory, a display, the camera, and the at leastone processor being integrated within the apparatus; determine atemplate associated with the process indicator, the determined templateincluding a template image of the process indicator and templatecomponents of the process indicator; and display the received image andthe determined template image such that the received image overlays thedetermined template image or the determine template image overlays thereceived image.
 39. The computer-readable storage media of claim 38,wherein the computer-executable instructions further cause the processorto characterize the process indicator using at least one of a shape of abezel of the process indicator, a shape of the scale of the processindicator, labels proximate the process indicator, and a color scheme ofthe process indicator.
 40. The computer-readable storage media of claim39, wherein the computer-executable instructions further cause theprocessor to optically recognize the labels.
 41. The computer-readablestorage media of claim 38, wherein the computer-executable instructionsfurther cause the processor to: extract one or more features of theprocess indicator in the received image; and retrieve a template from aplurality of predetermined templates stored in the memory, the retrievedtemplate including predetermined features that match the extracted oneor more features of the process indicator in the received image.
 42. Thecomputer-readable storage media of claim 38, wherein thecomputer-executable instructions further cause the processor to:correlate the determined position of the value indicator to a templateposition on the determined template image, the position of the valueindicator in the received image determined with respect to a scale ofthe process indicators shown in the received image and characters of adigital process indicator; and determine a process indicator displayedvalue based on the correlated position.